Suzuki TL1000R (1998-2002) [202/512] Gearshift linkage installation

Содержание

• Ùupbituwbiùpun uo 1
• Service manual 2
• Tl 1000r 2
• A warning 3
• Chassis 3
• Cooling system 3
• Electrical system 3
• Emission control information 3
• Engine 3
• Fl system and intake air system 3
• Foreword 3
• General information 3
• Group index 3
• Important 3
• Periodic maintenance 3
• Servicing information 3
• Suzuki motor corporation 3
• Component parts and work to be done 4
• How to use this manual 4
• To locate what you are looking for 4
• Symbol 5
• Abbreviations may be used in this manual 6
• Sae to former suzuki term only for u s a 7
• General info 9
• General information 9
• Awarning 10
• General precautions 10
• Warning caution note 10
• Fuel oil and engine coolant recommendation 12
• Serial number location 12
• Suzuki tl1000rw 98 model 12
• A warning 13
• Anti freeze engine coolant 13
• Brake fluid 13
• Engine coolant 13
• Engine oil 13
• Front fork oil 13
• Liquid amount of water engine coolant 13
• Water for mixing 13
• Break in procedures 14
• Cylinder identification 14
• General information 1 6 15
• Dimensions and dry mass 16
• Engine 16
• Specifications 16
• Transmission 16
• Capacities 17
• Chassis 17
• Electrical 17
• Country and area codes 18
• Periodic maintanance 19
• Periodic maintenance 19
• Periodic maintenance chart 20
• Periodic maintenance schedule 20
• Cycle has been operated under wet or rainy conditions 21
• Lubrication points 21
• Note before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motor 21
• Periodic maintenance 2 2 21
• Proper lubrication is important for smooth operation and long life of each working part of the motorcycle major lubrication points are indicated below 21
• Air cleaner 22
• Maintenance and tune up procedures 22
• A warning 23
• Spark plug 23
• Tappet clearance 25
• 9 periodic maintenance 28
• How to use this chart 28
• Option 28
• Tappet shim selection table intake z 28
• Tappet shim set 12800 41810 28
• Option гаррет shim set 12800 41810 29
• Periodic maintenance 2 10 29
• Tappet shim no 12892 41с00 ххх 29
• Tappet shim selection table exhaust 29
• Engine oil and oil filter 30
• Fuel hose 30
• Engine idle speed 31
• A warning 32
• Evaporative emission control system e 33 only 32
• Pair air supply system e 33 only 32
• Throttle cable play 32
• Throttle valve synchronization 32
• Clutch 33
• À warning 33
• Awarning 34
• Cooling system 34
• Drive chain 36
• Cautio 38
• Warning 38
• Steering 41
• Exhaust pipe bolt 42
• Front fork 42
• Rear suspension 42
• Chassis bolt and nut 43
• Compression pressure check 45
• Compression test procedure 45
• Oil pressure check 46
• Oil pressure test procedure 46
• Engine 47
• Engine components removable with engine in place 48
• Engine removal 49
• Engine removal and installation 49
• Engine installation 58
• Engine disassembly 63
• Engine disassembly and reassembly 63
• Engine reassembly 84
• Cautiqn 89
• A cautio 123
• A 1 engine 128
• Cam drive system description 128
• The tl1000rw cam drive system consists of the crankshaft the primary drive gear the no cam drive idle gear sprocket the no cam drive idle gear shaft sprocket the cam chains the no cam drive idle gears sprockets and the camshafts this system allows the cam drive gear diameter is much smaller than a conventional cam drive sprocket system and the cam drive gears are smaller so that overall cylinder height can be reduced the primary drive gear and the cam drive gears use scissors gears to eliminate backlash and reduce mechanical noise 128
• Cam timing table 132
• Camshaft removal 133
• Cylinder head removal 135
• Camshaft cylinder head inspection and service 140
• Awarning 148
• Cylinder head installation 152
• Camshaft installation 156
• Cylinder piston 159
• Cylinder piston removal 160
• Cylinder piston inspection 161
• Piston cylinder installation 164
• Clutch 167
• Clutch removal 168
• Clutch inspection 170
• Clutch installation 171
• Clutch release cylinder 174
• Water pump clutch cover 175
• Water pump clutch cover removal 176
• Water pump clutch cover inspection and service 177
• Water pump clutch cover installation 179
• Primary drive gear n0 cam drive idle gear shaft sprocket 181
• Primary drive gear removal 182
• No cam drive idle gear shaft sprocket removal 183
• N0 cam drive idle gear sprocket and no cam drive idle gear shaft sprocket inspection 184
• Primary drive gear inspection and service 184
• Primary drive gear installation 185
• No cam drive idle gear shaft sprocket installation 186
• Starter system generator crankshaft position sensor 187
• Starter torque limiter generator crankshaft position sensor removal 188
• Starter torque limiter generator crankshaft position sensor inspection and service 190
• Starter torque limiter generator crankshaft position sensor installation 193
• Starter motor inspection and servicing 195
• Starter motor installation 195
• Starter motor removal 195
• Gearshift linkage 197
• Gearshift linkage removal 198
• Gearshift linkage inspection and service 200
• Gearshift linkage installation 202
• Transmission crankshaft conrod removal 208
• Transmission inspection and service 208
• Engine 3h 6 213
• Conrod crank pin bearing inspection and service 215
• Conrod crankshaft inspection 215
• Crankcase crankshaft bearing inspection and service 218
• Crankshaft thrust clearance adjustment 222
• Transmission crankshaft conrod installation 223
• Engine lubrication system 225
• Oil pump 226
• Oil sump filter oil pressure regulator 228
• Oil pressure switch oil cooler 231
• Oil filter 232
• Oil pressure 232
• Piston cooling oil nozzle oil jet 232
• Engine lubrication system chart 234
• Engine lubrication system 235
• Fl system and intake air system 236
• Fuel injection system 236
• Connector coupler 238
• Precautions in servicing 238
• Ecm various sensors 239
• Electrical circuit inspection procedure 240
• Using testers 243
• Fl system technical features 244
• Injection time injection volume 244
• Compensation of injection time volume 245
• Injection stop control 245
• Fuel delivery system 246
• Fuel pump 247
• Fuel injector 248
• Fuel pressure regulator 248
• Fuel pump control system 249
• Ecm fl control unit 250
• A a a f a a a 251
• A a h ii 251
• Injection timing 251
• Y y y y y y 1 v y y ol y v y y y y y 251
• Sensors 252
• Intake air system technical features 256
• Intake air control valve 257
• Operation 258
• Fl system diagram 262
• Self diagnosis function 264
• User mode 264
• Dealer mode 265
• Fail safe function 267
• Customer complaint analysis 268
• Fl system trouble shooting 268
• Self diagnosis reset procedure 269
• Self diagnostic procedures 269
• Malfunction code and defective condition 270
• C11 cmp sensor circuit malfunction 272
• C12 ckp sensor circuit malfunction 273
• C13 iap sensor circuit malfunction 274
• U i i i rrnx 275
• C14 tp sensor circuit malfunction 276
• C15 ect sensor circuit malfunction 278
• I i i i i i i i i i i i i i i i i i 278
• I i n i i i i i i i i i m 278
• C21 iat sensor circuit malfunction 279
• C22 ap sensor circuit malfunction 280
• I i i i i i i m i i i i i n 281
• Ijj l l l ini nnnl l __________ __________ 281
• C23 to sensor circuit malfunction 282
• C24 or c25 ignition system malfunction 283
• C31 gear position gp switch circuit malfunction 283
• C32 c33 c34 and c35 fuel injection malfunction 284
• C41 fp relay circuit malfunction 285
• C42 ig switch circuit malfunction 285
• Awarning 286
• Fuel system 286
• Fuel tank lift up 286
• Fuel tank removal 286
• A warning 287
• Fuel pressure inspection 287
• Fuel tank installation 287
• A warning 288
• Fuel pump and fuel filter removal 288
• Fuel pump inspection 288
• Fuel pump relay inspection 288
• A warning 290
• Fuel mesh filter inspection and cleaning 290
• Fuel pump and fuel filter installation 290
• Construction 291
• Fl system and intake air system 4 54 291
• Throttle body 291
• Air cleaner box removal 292
• A warning 293
• Air cleaner box installation 293
• Throttle body removal 293
• Throttle body disassembly 294
• A warning 296
• Throttle body cleaning 296
• Inspection 297
• Throttle body reassembly 297
• Throttle body installation 302
• Warning 303
• Fast idle adjustment 305
• Fuel injector inspection 305
• Fuel injector installation 305
• Fuel injector removal 305
• Throttle valve synchronization 307
• Fast idle cable adjustment 310
• Throttle cable adjustment 310
• Throttle lever gap adjustment 310
• Throttle position sensor tps setting 310
• Intake air system 311
• Intake air system inspection 311
• Vcsv inspection 311
• Vtv inspection 311
• Cautio 312
• Intake air control valve actuator inspection 312
• Vacuum damper inspection 312
• Ckp sensor inspection 313
• Ckp sensor removal installation 313
• Cmp sensor inspection 313
• Cmp sensor removal installation 313
• Iap sensor inspection 313
• Iap sensor removal installation 313
• Sensors 313
• Tp sensor inspection 313
• Tp sensor removal installation 313
• Ap sensor inspection 314
• Ap sensor removal installation 314
• Ect sensor inspection 314
• Ect sensor removal installation 314
• Iat sensor inspection 314
• Iat sensor removal installation 314
• To sensor inspection 314
• To sensor removal installation 314
• Fl system and intake air system 4 78 315
• Throttle body reassembling information 315
• Cooling system 317
• Cooling system 320
• Description 320
• Construction 321
• A caution 322
• A warning 322
• Engine coolant 322
• A warning 323
• Radiator and water hoses 323
• Radiator removal 323
• A caution 324
• Awarning 324
• Inspection 324
• Cooling fan 326
• Remounting 326
• Removal 326
• Inspection 327
• Remounting 327
• A warning 328
• Cooling fan thermo switch 328
• Removal 328
• Inspection 329
• Installation 329
• Engine coolant temperature sensor 330
• Removal 330
• Warning 330
• Inspection 331
• Installation 331
• A warning 332
• Removal 332
• Thermostat 332
• Inspection 333
• Installation 334
• Water pump 334
• Chassis 335
• Removal 337
• Remounting 340
• Chassis 6 6 341
• Construction 341
• Front wheel 341
• Inspection and disassembly 343
• Removal 343
• Reassembly and remounting 345
• Cautio 346
• Construction 347
• Front fork 347
• Removal and disassembly 348
• Inspection 350
• Reassembly and remounting 351
• A warning 355
• Suspension setting 355
• Construction 356
• Removal and disassembly 356
• Steering 356
• Inspection and disassembly 359
• Reassembly and remounting 360
• Steering tension adjustment 364
• Construction 365
• Rear wheel 365
• Removal 367
• Inspection and disassembly 368
• Reassembly and remounting 369
• Description 371
• Rear suspension 371
• Rotary damper operation 372
• Construction 373
• Rotary damper unit and spring unit removal 375
• Rotary damper unit and spring unit inspection and disassembly 377
• Rotary damper unit and spring unit reassembly and remounting 379
• Final inspection and adjustment 381
• Suspension setting 381
• Rear swingarm removal 382
• Rear swingarm inspection and disassembly 384
• A caution 385
• Rear swingarm reassembly and remounting 386
• Final inspection and adjustment 388
• A warning 389
• Construction 389
• Front brake 389
• Brake fluid replacement 390
• Brake pad replacement 390
• A warning 391
• Caliper removal and disassembly 391
• Caliper inspection 392
• Caliper reassembly and remounting 392
• Brake disc inspection 393
• Master cylinder removal and disassembly 394
• Master cylinder inspection 395
• Master cylinder reassembly and remounting 395
• A warning 397
• Construction 397
• Rear brake 397
• Brake fluid replacement 398
• Brake pad replacement 398
• A cautio 399
• Awarning 399
• Caliper removal and disassembly 399
• Caliper inspection 400
• Caliper reassembly and remounting 400
• Master cylinder removal and disassembly 401
• Master cylinder inspection 402
• Master cylinder reassembly and remounting 402
• Clutch master cylinder 403
• Disassembly and reassembly 403
• Removal 403
• 69 chassis 404
• Note mark the tire with chalk to note the position of the tire on the rim and rotational direction of the tire 404
• Remove the valve core from the valve stem and deflate the 404
• The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead because of this we recommend using a tire changer which is also more efficient than tire levers for tire removal the following tools are required 404
• Tire and wheel 404
• Tire completely 404
• Tire removal 404
• Inspection 406
• Ia caution 407
• Tire installation 407
• Awarning 408
• Drive chain 409
• Drive chain cutting 409
• Awarning 410
• Drive chain connecting 410
• Electrical system 413
• Cautions in servicing 414
• Connector 414
• Coupler 414
• Semi conductor equipped part 414
• Battery 415
• Connecting battery 415
• Using multi circuit tester 415
• Wiring procedure 415
• Location of electrical components 416
• Charging system 418
• Description 418
• Troubleshooting 420
• Inspection 421
• Battery 423
• Electrical system 7 10 423
• Side stand ignition interlock system description 423
• Starter system and side stand ignition interlock system 423
• Starter system description 423
• The starter system consists of the following components the starter motor starter relay clutch lever posi tion switch turn signal side stand relay side stand switch gear position switch starter button engine stop switch ignition switch and battery pressing the starter button on the right handlebar switch energizes the starter relay causing the contact points to close thus completing the circuit from the starter motor to the battery the starter motor draws about 80 amperes to start the engine 423
• This side stand ignition interlock system prevents the motorcycle from being started with the side stand down the system is operated by an electric circuit provided between the battery and ignition coils 423
• Troubleshooting 425
• Starter motor inspection 426
• Starter motor removal and disassembly 426
• Starter motor reassembly 427
• Starter relay inspection 428
• Side stand ignition interlock system part inspection 429
• Description 432
• Ignition system 432
• A caution 433
• Electrical system 7 20 433
• Engine can run over 10 600 r min without load even if the ignition cut off circuit is effective and it may cause engine damage do not run the engine without load over 10 600 r min at anytime 433
• Front rear 433
• Ignition timing map 433
• Note the ignition cut off circuit is incorporated in this ecm to prevent over running engine if engine rpm reach es 10 600 r min this circuit cuts off the ignition primary current for all spark plugs 433
• Wire color 433
• Troubleshooting 434
• Awarning 435
• Inspection 435
• Combination meter 439
• Disassembly 439
• Removal 439
• 27 electrical system 440
• Inspection 440
• Using the tester check the continuity between terminals in the following diagram if the continuity measured is incorrect re move and check the bulb if the bulb is failure install the new bulb and check the continu ity again if the bulb is correct replace the unit with a new one 440
• _____ j 441
• Headlight 445
• Brake light taillight license light and turn signal light 446
• Fuel pump relay 447
• Starter relay 447
• Turn signal side stand relay 447
• Switches 448
• Battery 449
• Initial charging 449
• Specifications 449
• Servicing 450
• Recharging operation 451
• Servicing info 453
• Servicing information 453
• Fl system malfunction code and defective condition 454
• Troubleshooting 454
• Engine 456
• Radiator cooling system 461
• Chassis 462
• Brakes 463
• Electrical 464
• Battery 465
• For e 04 18 22 25 34 37 468
• Servicing information 8 16 469
• Sss 555 469
• Мпз ммииса1 469
• Тег 469
• 17 servicing information 470
• For e 24 470
• Wire harness cable and hose routing 472
• Wire harness routing 472
• Servicing information 8 20 473
• 21 servicing information 474
• Cable routing 475
• Servicing information 8 22 475
• 25 servicing information 478
• Fuel tank drain hose routing 478
• Section b b 479
• Section c c 479
• 27 servicing information 480
• Front brake hose routing 480
• Rear brake hose routing 481
• Servicing information 8 28 481
• Clutch hose routing 482
• Pair air supply system hose routing 483
• Servicing information 8 36 489
• Special tools 489
• 37 servicing information 490
• Note when order the special tool please confirm whether it is available or not 491
• Servicing information 8 38 491
• Engine 492
• Tightening torque 492
• Chassis 493
• Tightening torque chart 495
• Camshaft cylinder head 496
• Service data 496
• Valve guide 496
• Cylinder piston piston ring 497
• Clutch 498
• Conrod crankshaft 498
• Oil pump 498
• Thermostat radiator fan 499
• Transmission drive chain 499
• Fi sensors intake air control valve 500
• Injector fuel pump fuel pressure regulator 500
• Throttle body 500
• Electrical 501
• Wattage 501
• Brake wheel 502
• Suspension 503
• Tire pressure 503
• Fuel oil engine coolant 504
• Emission control 505
• Emission control information 505
• Evaporative emission control system california model only 506
• Fuel injection system 506
• Canister 508
• Evaporative emission control system inspection california model only 508
• Tank pressure control valve 508
• Warning 508
• Emission control information 9 4 509
• Pair air supply system diagram 509
• Pair air supply system hose routing 510
• Hoses and pipes 511
• Pair air supply system inspection california model only 511
• Pair control valve 511
• Reed valve of pair control valve 511
• Suzuki motor corporation 512

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3G 5 ENGINE GEARSHIFT LINKAGE INSTALLATION Installation is in the reverse order of removal NOTE Refer to the following pages for the details of each step Install Gearshift arm stopper bolt Gearshift cam stopper Gearshift cam plate See p 3 43 Gearshift shaft gearshift arm See p 3 43 Gasket Dowel pins See p 3 44 Gearshift cover See p 3 44